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GREASES FOR MINING EQUIPMENTS
Augusto Fernandes Product Application Specialist
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Introducing Shell Lubricants
18 grease manufacturing plants
Expert advice, practical tools and training
Grease specialists in the field worldwide
370 technical field staff and 30 product specialists
Customers in over 70 countries
Major global lubricants supplier
3,000+ employees across the global supply chain
R&D centres on four continents
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SHELL GADUS S4 OG A HIGH-PERFORMANCE OPEN-GEAR GREASE
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What Drives the Mining Equipments Market?
Energy Efficiency
Reduced Emissions
Increased Power Output
Extended Equipment
Life
Extended Service Intervals
Market Influence:
Legislation Market Influence:
Technology
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Evolution of Mining Equipments and Components
Euclid 10 ton
2020
Komatsu 50 ton 600 hp
70s Caterpillar
400 ton 4,000 hp
Nowadays
Komatsu 190 ton
2,000 hp
90s
Near Future
Belaz 450 ton
4,600 hp
Contamination Sensitivity
Vane Pum p
Piston Pum p
Gear Pum p
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Shell Gadus S4 OG Designed to Improve Profitability
At Shell Lubricants we appreciate that, in tough conditions and in remote areas, you are constantly striving to:
Maximise machine availability Drive down production costs Cut maintenance costs
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Working With the Mining Industry
Shell Lubricants is a leading supplier of oils, greases and fluids to the mining industry, providing:
Pioneering research centres and innovative technical partnerships to help our lubricants deliver excellent component protection.
On-the-ground experts to help analyse your needs and solve your lubrication problems, thereby unlocking your mining potential.
International resources offering security of supply and consistently high-quality products and services.
A comprehensive range of lubricants and services for mining operations.
Experience working with leading mining companies, including Anglo American, Barrick Gold, BHP Billiton, Rio Tinto, Thiess, Vale and Xstrata.
Over 4,000 equipment manufacturer approvals across the product range.
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Shell Gadus S4 OG Outstanding Protection
Our newly extended open-gear grease range offers outstanding protection across all seasons and climates:
Shell Gadus S4 OGT for warm climates and extreme hot weather
Shell Gadus S4 OGXK for cold climates and sub-Arctic winters
Shell Gadus S4 OG Multi-Season our universal mid-range temperatures product.
These products are suitable for open gears on mobile mining equipment such as shovels, excavators and hoists. They meet equipment manufacturer specifications including CAT SD4713, P&H 520 and P&H 464.
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Shell Gadus S4 OG Wide Temperature Range
Shell Gadus S4 OG is fully compatible with aluminium complex greases.
Shell Gadus S4 OGXK
Shell Gadus S4 OG MS
Shell Gadus S4 OGT
Temperature range, C -45C to +10C -20C to +40C -7C to +50C
NLGI 00/000 0/00 0
Base Fluid Viscosity, cSt* 4,000 4,000 5,500
45 30 20 7 0 +10 +20 +30 +40 +50
Temperature Range, C
Shell Gadus S4 OGXK
Shell Gadus S4 OG MS
Shell Gadus S4 OGT
*1cSt = 1mm2/sec
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Shell Gadus S4 OG Meeting Tough Challenges
The Shell Gadus S4 OG product range offers protection during:
Extreme heavy-duty applications, sustained heavy loads and shock loads. Severe environmental conditions. A wide range of ambient temperatures and significant daily and seasonal
temperature variations.
Long operating hours with a focus on productivity and minimum, planned downtime for maintenance.
It meets increasingly challenging equipment manufacturers lubricant performance requirements.
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Shell Gadus S4 OG Exceeds Load-Carrying Needs
The Shell Gadus S4 OG product range helps to prevent damage to gear teeth from shock loading, for reduced downtime and maintenance costs and extended equipment life. It incorporates:
A specially designed anti-wear, extreme-pressure (EP) additive package*: >15% solid additives, including 5% MoS2.
Optimised for use with the aluminium complex thickener.
Ultra-high-viscosity base oils that: Far exceed equipment manufacturers requirements.
Offer heavy-duty protection.
Synthetic technology, which: Maintains excellent flow properties across the operational temperature range.
Has flow properties that are achieved without viscosity modifiers.
Our products meet the essential 800-kg four-ball weld load specification.
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Shell Gadus S4 OG Exceeds Load-Carrying Needs
*Calculated from data obtained from the Four-Ball EP method according to ASTM D2596
0 50 100 150 200
Load wear index, kg
Warm Weather Products
(-20C or higher)
Cold Weather Products
(-20C or lower)
Shell Competitors
120
Better Protection
Shell Gadus S4 OG lubricants all comfortably exceed the minimum threshold of 120 in the load wear index*, which measures the ability of a lubricant to prevent wear under applied loads.
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Shell Gadus S4 OG Outstanding Adhesiveness in Harsh Conditions
To protect effectively, open-gear lubricants must prevent metal-to-metal gear tooth contact, even under sustained and shock loads, in the presence of water and other contaminants. Adhesiveness is critical. Shell Gadus S4 OG lubricants offer: Minimal wash-off, fling-off or squeeze out
(displacement under load).
A highly persistent lubricant film on gear teeth.
Outstanding protection, even in challenging wet or dusty environments.
In water spray-off tests, Shell Gadus S4 OGT showed negligible loss.*
* Based on ASTM D4049 water spray-off test
80 60 40 20 0
Water spray off, %
Shell Competitors
Better Water-Wash-Off Resistance
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Shell Gadus S4 OG Outstanding Adhesiveness in Harsh Conditions
Shell Gadus S4 OG is formulated with: A special aluminium complex thickener modified for adhesiveness. High-quality, high-viscosity base oils to deliver good film thickness, even under high
pressure.
Anti-rust additives to enhance corrosion protection for components.
Caterpillar shovel showing good product film adherence with Shell Gadus S4 OG
TZ shovel at the same site showing poor lubricant adherence (competitor product)
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Helping You Add Value
Meets the specifications of leading equipment manufacturers, including Caterpillar and P&H.
Shells optimised aluminium complex thickener formulation.
Ultra-high viscosity base oil, with synthetic or semi-synthetic components.
Specially formulated additive package, including 5% moly, and overall >15% solids.
Formulated without solvents or bitumen.
SHELL GADUS S4 OG
Maintains high productivity across long working hours with limited downtime for servicing and maintenance.
Extends component life and reduces component failure caused by wear or corrosion.
Simplifies lubricant inventory.
DESIGNED TO HELP MINING OPERATORS
NEXT LEVEL OF PERFORMANCE
Provides the high level of protection required by equipment manufacturers.
Outstanding adhesiveness.
Persistent lubricant film.
Long effective lubricant lifetime.
Reliable pumpability and sprayability.
Environmentally considerate.
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Shell Gadus S4 OG Clear Oil 20000 Advanced Open Gear Lubricant
Shell Gadus S4 OG Clear Oil 20000 is advanced part-synthetic non-bitumastic viscous lubricant specifically developed to satisfy the demands of heavily loaded open gearing.
This product was primarily designed for fixed plant (mills, kilns) for gears in vertical orientation. Shell Gadus S4 OG Clear 20000 is approved and recommended for the main Mills & Kilns OEMs as Metso, FLSmidth and Ferry Capitain.
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Shell Gadus S4 OG Clear Oil 20000 Exceeds Load-Carrying Needs
The Shell Gadus S4 OG Clear Oil 20000 helps to prevent damage to gear teeth heavily loaded, for reduced downtime and maintenance costs and extended equipment life. It incorporates: Extreme pressure performance: The high viscosity base oils are combined with extreme pressure additives to give the lubricant
very high film strength and extreme load carrying capability needed for the protection or heavily loaded open gearing.
Ultra-high-viscosity base oils The use of synthetic oil with thickening has produced a lubricant with high viscosity index, which
provides good pumpability at low temperatures while maintaining high viscosity at elevated temperatures.
Easier gear inspections: Static and dynamic inspections are much easier to view the gear condition without cleaning off the
grease or oil, as the lube film is clear, can inspect the gearing through the lube film
Shell Gadus S4 OG Clear Oil 20000 meets the essential 800-kg four-ball weld load specification.
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Shell Gadus S4 OG Clear Oil 20000 Easier Gear Inspections
Open gear with Shell Gadus S4 OG Clear Oil 20000 (much easier to view the gear condition)
Open gear with a typical OGL (much harder to view the gear condition)
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Complete Range of Open-Gear Lubricants
Products Applications
Shell Gadus S4 OG Advanced protection for mobile mining equipment that meets the latest specifications from leading equipment manufacturers.
Shell Gadus S2 OG
A comprehensive, versatile range with a long service history and established reputation for use in mobile and fixed plant applications, including gears and journal bearings on mills and kilns, as well as on wire ropes.
Shell Gadus S2S4 OG Clear Oils
Lubricants for fixed plant, including mills and kilns, whatever the lubricant delivery system, offering easier gear inspections because of the clear lubricant film.
Shell Gadus S3 Repair A sprayable running-in and repair grease for open gears. Smoothes surface roughness, increases contact area for loading and helps to reduce maintenance requirements.
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Gadus S3 V460XD Premium Multipurpose Grease for Mining Equipments
Shell Gadus S3 V460XD Greases are premium heavy-duty greases designed for use in a wide range of mining applications with shock loaded, heavy-duty slow moving bearings and non-bearing applications in Shovels, Excavators, Haul Trucks, Tractor and industrial equipments.
Shell Gadus S3 V460XD Greases help improve the life of moving bearings and non-bearings heavily loaded, reducing downtime and maintenance costs: Wide Operating Temperature Range: Prolonged Grease Service Life Excellent Mechanical Stability For Shock Loaded Conditions Enhance Extreme Pressure and Antiwear Properties Low Water Wash-Out Effective Corrosions Protection
Approvals and Recommendations Shell Gadus S3 V460XD meets following OEM specifications: Komatsu Komatsu Trucks Terex Liebherr Trucks P&H BE (certified) Caterpillar (exceeds specification)
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Shell Gadus Product Chart for Mining
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SHELL LUBEEXPERT
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Shell LubeExpert
1994
Australia
Experts Team
deep knowledge in mining equipment
wide expertise in lubrication
Critical Assets
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Shell LubeExpert
MTTR MTBS
Components Life Identify Premature Failures Unscheduled Downtime
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Shell LubeExpert Focus in Critical Assets
Mills
Draglines
Shovels
Excavators
Haul Trucks
Reclaimers
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Shell LubeExpert
Management Operational Support
Productivity
Availability
Reliability
Safety
+
Help them stay in control
Extending best practices
Total Productivity Maintenance (TPM) and Reliability Centered Maintenance (RCM)
Only successful with proactive personnel like LSEs
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Shell LubeExpert: Developing LSE Capability
Lubrication Audits Setting Performance Standards
Three years to fully train a LSE to be competent in all aspects of the role
Three increasing levels of competency development
Five years of experience assembling and rebuilding critical equipment Shells comprehensive training and field coaching
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Shell LubeExpert Services Overview
Operational inspections Visual, Temperature, and Strobe-O-Scope Thermal Imaging Vibration analysis
Shut Down Inspections Visual inspections, Lubrication system audit, and spray
pattern monitoring Tooth profiling Hardness testing Deflection checks Specialty product conversion
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Shell LubeExpert Operational Inspections
Mills, kilns and draglines dont shut down often Visual, temperature and strobe-o-scope Inspected for: Blockages
Correct spray patterns
Leaking seals
Identify gear teeth misalignment
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Shell LubeExpert Operational Inspections
Quality Inspection Reports
Checklist of inspection points Comprehensive review and issue report Also provide advice on required repairs Assessment of open gear and bearing lubrication Complete report using iPad/tablet Should be conducted monthly
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Shell LubeExpert Advanced Operational Inspections
Thermal Imaging
Video 01
Video 02
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Shell LubeExpert Advanced Operational Inspections
Vibration Monitoring
Temperature Tags
Used while in operation Accelerometers and Tachometers Compared over time, detecting possible wear All rotating equipment vibrates to some degree Older bearings and components vibrate more dramatically Monitoring identifies this before it becomes a problem LSEs with level 2 or above certification Correlating vibration with oil analysis can be provided
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Shell LubeExpert Basic Shut down Inspections
Equipment is switched off and isolated for maintenance Its the only time LSEs can access the isolated machine Reveal hidden facts How often and how much Check gearing alignment and lubricants evenness View the gears condition See any damage or fatigue Involve detailed work that can be time consuming Every lubricant injector is operated and examined Should be conducted at least twice a year
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Shell LubeExpert Basic Shut down Inspections
Routine spray pattern checks Too much air pressure Not enough air pressure
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Shell LubeExpert Shut Down Inspections
Tooth Tape Carbon Impressions
(used to monitor fatigue, pitting,
spalling)
Tooth Measuring
Hardness Testing
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Shell LubeExpert Support Focus Troubleshooting
Bull Gear
New Pinion
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Shell LubeExpert Support Focus Failure Diagnostics
Understanding how it failed
The root cause of failure, has to be know to prevent it from occurring again in the future
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Shell LubeExpert Support Focus Training
Skills and competences
Safe working procedures (SWP)
Job Safety Analysis (JSA)
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Success Case (Demonstrated Value Records DVRs)
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Success Case 01 Chaneme (Hitachi Dealer) Shell Gadus S2 OG 85 Pins & Bushes Hitachi Excavators
1 2 3 CHALLENGE SOLUTION OUTCOME
VALUE 4
Chaneme (Hitachi Dealer in Colombia) in coal mine in Calenturitas Colombia maintains 5 excavators Hitachi EX 3600-5.
Chaneme wanted to increase the pins & bushes life beyond the current 4,000 hrs.
Shell, through Shell LubeExpert, identified the failures causes and proposed the use of a high-performance grease (Shell Gadus S2 OG 85).
By identifying the failures causes, implementation of a routine inspection process of lubrication system and critical components, together with the application of high performance grease (Shell Gadus S2 OG 85) the pins and bushes life increased from 4,000 hrs to 16,000 hrs.
Savings of over USD 600,000.00 with increase of productivity and with life extension of pins and bushes
Increased pins and bushes life from 4,000 hrs to 16,000 hrs
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.
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Success Case 02 Albian Sands Energy Shell Gadus S4 OGK/OGXK Saddle Block Liners
1 2 3 CHALLENGE SOLUTION OUTCOME
VALUE 4
Albian Sands Energy in Fort McMurray Canada operates 10 Bucyrus 495 HF shovels.
The key challenge was cold temperature and the ability of the product to not just pump through the system, but be robust enough that it provided the best lubrication during winter.
Shell, through Shell LubeExpert, made a detailed analysis and inspection of the application and proposed the use of a high-performance lubricant for saddle block liners, open gears, boom and revolving frame (Shell Gadus S4 OGK/OGXK).
By implementing of a routine inspection process of the lubrication system and the critical components of the shovels, together with the application of high performance grease (Gadus S4 OGK/OGXK) the saddle block liners life achieved over 32,000 hrs against a estimated life of 10,000 hrs.
Savings of over USD 1,800,000.00/year with increase of productivity and with life extension of saddle block liners
Increased saddle block liners life from 10,000 hrs to 32,000 hrs
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.
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Success Case 03 Iron Ore Mining in Brazil Shell Gadus S3 V220C 2 Bearing of the Bucket Wheel
1 2 3 CHALLENGE SOLUTION OUTCOME
VALUE 4
Iron ore mining in Brazil operates a ThyssenKrupp 5PA5A reclaimer.
The challenge was increase the bearing of the bucket wheel life beyond the current 4,000 hrs.
Shell, through Shell LubeExpert, identified the failures causes and proposed the use of a high-performance grease (Shell Gadus S3 V220C 2).
By implementation of a routine inspection process of the lubrication system, resizing of bearings sealing and application of a high performance grease (Gadus S3 V220C 2), the bearing life increased from 4,000 hrs to over 8,600 hrs.
Savings of over USD 2,000,000.00/year with increase of productivity and with life extension of the bucket wheel bearing
Increased bucket wheel bearing life from 4,000 hrs to 8,600 hrs
Significantly reduction the reclaimer unavailability and therefore increased its productivity
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.
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Success Case 04 The Lagunas Norte Mine in Peru Shell Tactic EMV Conveyor Belt Bearings
1 2 3 CHALLENGE SOLUTION OUTCOME
VALUE
Lagunas Norte was previously using Shell Gadus S2 V220 2 grease for manual lubrication. The greasing schedule was not always completed, and irregular lubrication, together with contamination by dirt, dust and water, was causing the production belt bearings to wear. Consequently, the company experienced unscheduled stoppages and production losses.
Shell Lubricants recommended the installation of a Shell Tactic EMV automated grease dispensing unit pre-filled with Shell Gadus S3 T220 2 grease, and staff training using the Shell LubeCoach service. Shell Tactic EMV lubricating units were installed at two critical production points to supply precise, reliable and regular amounts of grease to the machines.
After implementing the recommended solution, Lagunas Norte experienced: a decrease in manual lubrication time that enabled technical staff to attend previously neglected areas. the elimination of premature bearing failures through reliable and regular lubrication. peace of mind from knowing that the greasing was automated and set specifically for the machines requirements.
By identifying the mines need for greasing support and a premium grease to perform well in a high-contamination environment, Shell was able to recommend a solution that met both requirements. Lagunas Norte reported a potential annual saving of US$167,417 as a result of implementing the solution.
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices.
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